Cross car duct with integrated mode doors and hvac module

ABSTRACT

A cross car duct for use in an instrument panel assembly of an automotive vehicle includes an upper beam of one piece molded plastic extending longitudinally between opposing A-pillars of the vehicle. The cross car duct also includes a lower beam of one piece molded plastic attached to the upper beam and extending longitudinally between the A-pillars. A magnesium steering column support for supporting conventional steering components on the cross car duct is fixedly secured to the upper beam. The upper beam includes a plurality of air ducts and the lower beam includes a plurality of air openings aligned with the air ducts for passing air through the beams. The lower beam also includes a housing for supporting an HVAC module. The cross car duct further includes a plurality of integrated mode doors and actuators operatively connected to the housing of the lower beam for actuation between an open position spaced from the air openings and a closed position covering the air openings in the lower beam. The HVAC module includes a lower casing integrated with the housing of the lower beam for supporting and enclosing the mode doors and the components of the HVAC module in the lower beam forming a cross car duct with integrated mode doors and an integral HVAC module.

FIELD OF THE INVENTION

[0001] The present invention relates generally to a cross car duct foran automotive instrument panel assembly, and more particularly, to across car duct having a magnesium structural steering column support,integrated mode doors, and a heating, ventilating, and air conditioningmodule for the instrument panel assembly.

BACKGROUND OF THE INVENTION

[0002] Automotive vehicles typically include an instrument panelassembly secured between a pair of vertical stanchions, or A-pillars,along opposite sides of the vehicle and in front of the passenger and/ordriver compartment of the vehicle. The instrument panel assemblycommonly supports a plurality of components such as radio units,steering components, glove box components, gauges, and a heating,ventilating and air conditioning unit (HVAC unit). Instrument panelassemblies are commonly constructed by one or more magnesium, steel orplastic molded cross car beams extending between the A-pillars forsupporting the various instrument panel components and providingstructural rigidity between the A-pillars. The plastic molded beams mayinclude channels and openings for receiving and supporting the variouscomponents therein.

[0003] The HVAC unit commonly comprises an upper casing and a lowercasing for housing the HVAC components such as an evaporator core,filter, heater core and actuated valves and mode doors for directing theflow of air from the HVAC unit through selective openings in the upperand lower casings. The HVAC unit is fixedly secured to the cross carbeams. However, the openings in the upper and lower casings of the HVACunit must be aligned with openings in the beams in order to circulateand direct the flow of air from the HVAC unit through the beams and intothe vehicle compartment.

[0004] Therefore, it is desirable to provide a structural plastic crosscar beam having integrated air ducts for circulating air therethroughand to integrate the components of the HVAC unit into the structuralbeams to decease the number of parts, weight and assembly complexity ofthe instrument panel.

SUMMARY OF THE INVENTION

[0005] According, the present invention relates to a cross car duct foruse in an instrument panel assembly of an automotive vehicle comprisinga contoured upper beam extending longitudinally between a first end anda second end and having a plurality of air ducts forming air outlets.The cross car duct further includes a contoured lower beam extendinglongitudinally between a first end and a second end and attached to theupper beam between the respective first and second ends. The lower beamhas a plurality of air openings aligned with the air ducts of the upperbeam. The cross car duct also includes at least one mode dooroperatively connected to the lower beam adjacent at least one of the airopenings and at least one actuator secured to the lower beam foractuating the mode door between a closed position covering the airopening and an opened position spaced from the air opening for openingthe air opening to allow passage of air therethrough. The cross car ductadditionally includes a heat, ventilating and air conditioning modulesecured to the lower beam for circulating ambient air through selectiveair openings and air ducts dependent on the actuator controlling theactuation of the mode door between the opened and closed positions.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006]FIG. 1 is a partially exploded perspective view of the subjectinvention;

[0007]FIG. 2 is a bottom view of a lower beam of the cross car duct andthe integrated mode doors;

[0008]FIG. 3 is a cross-sectional view of the cross car duct withintegrated mode doors and HVAC module;

[0009]FIG. 4 is a partially exploded perspective view of the lower beamand HVAC module;

[0010]FIG. 5 is an assembled view of FIG. 4; and

[0011]FIG. 6 is an assembled view of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0012] Referring to the Figures, a cross car duct for use in instrumentpanel assembly of an automotive vehicle is generally depicted at 10 inFIG. 1. The cross car duct 10 includes a contoured upper beam 12extending longitudinally between a first end 14 and a second end 16opposite the first end 14. The upper beam 12 is constructed of a onepiece, injection molded or compression formed plastic, such as athermoplastic, thermoset, filled or reinforced plastic. The upper beam12 includes a thin walled main body portion 18 having a generallyS-shaped cross-section. A plurality of mounting flanges 20, 21, 22,project outwardly from the main body portion 18 for securing andsupporting components of the instrument panel assembly, such as steeringcomponents, glove box components, etc. A mounting flange 24 projectsdownwardly from the main body portion for securing and supporting aheating, ventilating and air conditioning unit, or HVAC module, as shownat 25 and as will be described in further detail hereinbelow. The upperbeam 12 further includes a plurality of front air ducts 26 a-d and arear air duct 27 defined by openings in the main body portion 18 formingair outlets.

[0013] The cross car duct 10 further includes a contoured lower beam 28extending longitudinally between a first end 30 and a second end 32 forsupporting components of the heating, ventilating and air conditioningunit 25. The lower beam 28 is also constructed of a one piece, injectionmolded or compression formed plastic, such as a thermoplastic,thermoset, filled or reinforced plastic. The lower beam 28 includes athin wall main body portion 34 also having a generally S-shapedconfiguration for mating alignment and engagement with the upper beam 12between the respective first ends 14, 30 and second ends 16, 32. Morespecifically, the lower beam 28 is bonded or fixedly secured, such as byvibration welds, to the upper beam 12 to longitudinally align therespective first ends 14, 30 and the second ends 16, 32. The contours ofthe mating upper 12 and lower 28 beams define air channels 31, 33extending longitudinally between the respective first and second ends toallow pass-flow of air therealong.

[0014] A generally rectangular housing 36 extends downwardly from themain body portion 34 for cooperating with and enclosing the upperportion of the HVAC module 25. Referring to FIG. 2, the underside of thelower beam 28 is shown. The housing 36 is shown including a planar frontwall 38, rear wall 40 and parallel side walls 42, 44 extending betweenthe front wall 38 and rear wall 40.

[0015] Referring again to FIG. 1, the lower beam 28 further includes aplurality of front air openings 46 passing through the main body portion34 and aligned with the openings formed by the respective plurality offront air ducts 26 b and 26 c in the upper beam 12. The lower beam 28also includes a rear opening 48 passing through the main body portion 34and aligned with the openings formed by the rear air duct 27 in theupper beam 12.

[0016] The cross car duct 10 also includes a plurality of mode doors 50,52 and 54 operatively connected to the lower beam 26 adjacent to the airopenings 46, 48. More specifically, referring to FIGS. 1, 2 and 3, eachmode door, 50, 52, 54 includes a generally flat panel 56 extendingoutwardly from a pivot rod 58. The pivot rod 58 of each mode door 50,52, 54 is pivotally connected between the opposing and parallel sidewalls 42, 44 of the housing 36. The mode door 50, or front door, ispivotally secured to the housing 36 immediately adjacent the front airopenings 46. The mode door 52, or defrost door, is pivotally secured tothe housing 36 immediately adjacent the rear air opening 48. Finally,the mode door 54, or bypass door, is pivotally secured to the housing 36below the rear air opening 48 and defrost door 52. Each of the modedoors 50, 52, 54 pivot between an open position and a closed positionfor controlling the flow of air from the HVAC module 25 through thebeams 12, 28 as will be described in greater detail below.

[0017] The cross car duct 10 also includes a plurality of actuators 60secured to the lower beam for actuating the mode doors 50, 52, 54between the closed position covering the air openings 46, 48 and theopened position spaced from the air openings 46, 48 to allow air fromthe HVAC module 25 to pass through the air ducts 26 a-d, 27 and into thevehicle compartment. More specifically, referring to FIGS. 2 and 3, afirst actuator 60 a is operatively connected to the front mode door 50for pivoting the mode door 50 between the closed position covering thefront air openings 46 and the opened position allowing passage of airthrough the front air openings 46 and the front air ducts 26 a-d. Asecond actuator 60 b is similarly operatively connected to the defrostmode door 52 for pivoting the door 52 between the closed positioncovering the rear opening 48 and the opened position allowing passage ofair through the rear opening 48 and rear air duct 27. A third actuator60 c is operatively connected to the bypass mode door 54 for pivotingthe door 54 between a closed position extending between the HVAC module25 and the defrost mode door 52 for preventing passage of air directlyto the openings 46, 48 and an opened position spaced from the defrostmode door 52 and opening 48 to allow passage of air to the openings 46,48.

[0018] Referring to FIGS. 3 and 4, the cross car duct 10 additionallyincludes a heating, ventilating and air conditioning unit, or HVACmodule, 25 for conditioning and circulating ambient air throughselective air opening 46, 48 and air ducts 26 a-d, 27 dependent on theactuators 60 controlling the actuation of the mode doors 50, 52, 54between the opened and closed positions. The HVAC module 25 includes alower casing 62 for engaging and closing the housing 36 in the lowerbeam 28. The HVAC module 25 is secured to the housing 36 of the lowerbeam 28 forming an enclosure between the lower casing 62 and the housing36. The HVAC module 25 includes a plurality of components commonly knownin the art, which are thus enclosed between the lower casing 62 and thehousing 36 and integrated with the lower beam 28. The HVAC module 25includes a filter 64, an evaporator 66 attached to the filter 64, aheater core 68 extending between the bottom of the lower casing 62 andthe bypass mode door 54, and a plurality of lower mode doors andactuators 70 in the casing for opening and closing passageways 71 in thelower casing 62. The HVAC module 25 further includes a fresh air inlet72 for supplying fresh ambient air to the HVAC module 25.

[0019] The cross car duct 10 further includes a magnesium steeringcolumn support 80 die cast by conventional manufacturing methods forsupporting conventional steering components on the cross car duct 10.The support 80 includes an upper plate 82 and a front plate 84. Thesupport 80 generally conforms to the contour of the upper beam 12 and isfixedly secured thereto by fastening the plates 82, 84 to the mountingflanges 20, 21. The support 80 further includes mounting brackets 86, 88for fixedly securing the support 80 to the vehicle structure to provideadditional support to the steering components.

[0020] In operation, referring to FIG. 3, ambient air is drawing intothe HVAC module 25 through the air inlet 72. The air passes through thefilter 64 and evaporator 62 to condition the air. If the HVAC module 25is in a heating condition, the bypass mode door 54 is closed by theactuator 60 c and the air passes through the heater core 68. Theactuators 60 a, 60 b control the opening of the front mode door 50 anddefrost mode door 52, respectively, between the opened and closedpositions based on operator selection to circulate the heated airthrough the air openings 46, 48 and air ducts 26 a-d, 27 of the beams12, 28. The heated air may also flow through the passageways 71 in thelower casing 62 by actuation of the actuators and lower mode doors 70.If the HVAC module 25 is in a ventilating or air conditioning condition,the bypass mode door 54 is opened by the actuator 60 c and the airbypasses the heater core 68 to the various selected air openings 46, 48and air ducts 26 a-d.

[0021]FIG. 4 discloses the mode doors 50, 52, 54 attached to the housing36 of the lower beam 28 and the HVAC module 25 positioned below thelower beam 28 for mating engagement and attachment with the housing 36.FIG. 5 discloses the mode doors 50, 52, 54 and the HVAC moduleintegrally attached to the housing 36 of the lower beam 28. Finally,FIG. 6 discloses the completely assembly cross car duct 10 withintegrated mode doors 50, 52, 54 and HVAC module 25.

[0022] The present invention has been described in an illustrativemanner. It is to be understood that the terminology which has been usedis intended to be in the nature of words of description rather than oflimitation. Many modifications and variations of the present inventionare possible in light of the above teachings. Therefore, within thescope of the appended claims, the present invention may be practiceother than as specifically described.

1. A cross car duct for use in an instrument panel assembly of anautomotive vehicle comprising: a contoured upper beam extendinglongitudinally between a first end and a second end and having aplurality of air ducts forming air outlets; a contoured lower beamextending longitudinally between a first end and a second end andattached to said upper beam between said respective first and secondends, said lower beam having a plurality of air openings aligned withsaid air ducts of said upper beam; an air channel formed between saidupper beam and said lower beam for supplying air to each of said airducts and said air openings; a steering column support affixed to saidupper beam and adapted to be directly attached to the vehicle and tosupport steering components of the vehicle; a mode door operativelyconnected to said lower beam adjacent at least one of said air openings;an actuator secured to said lower beam and operably connected to saidmode door for actuating said mode door between a closed positioncovering said air opening and an opened position spaced from said airopening for opening said air opening to allow passage of air; and aheat, ventilating and air conditioning (HVAC) module secured to saidlower beam for circulating ambient air through selective ones of saidair openings and said air ducts dependent on said actuator controllingsaid actuation of said mode door between said opened and closedpositions.
 2. (Canceled)
 3. (Canceled)
 4. A cross car duct as set forthin claim 1 wherein each of said upper beam and said lower beam is formedof plastic.
 5. A cross car duct as set forth in claim 4 wherein saidlower beam includes a thin wall main body portion supporting a housingand said HVAC module including a lower casing for mating with saidhousing for securing and enclosing said HVAC module with said lowerbeam.
 6. A cross car duct as set forth in claim 5 wherein said upperbeam includes a thin wall main body potion supporting a mounting flangefor fixedly securing and supporting said HVAC module to said upper beam.7. A cross car duct as set forth in claim 6 wherein said upper beamincludes a plurality of front air ducts defining air openings in fluidcommunication with a first air channel between said upper and lowerbeams and a rear air duct defining an air opening in fluid communicationwith a second air channel between said upper and lower beams.
 8. A crosscar duct as set forth in claim 7 wherein said lower beam includes aplurality of front air openings aligned with said front air ducts and influid communication with said first air channel and a rear air openingaligned with said rear air duct and in fluid communication with saidsecond air channel.
 9. A cross car duct as set forth in claim 8 furtherincluding a plurality of mode doors pivotally supported by said housingof said lower beam for opening and closing said front and rear airopenings to the passage of fluid therethrough.
 10. A cross car duct asset forth in claim 9 wherein said HVAC module includes an air inlet forsupplying air through said HVAC module to each of said air openings andair ducts in said respective lower and upper beams.
 11. A cross car ductas set forth in claim 10 wherein said HVAC module includes a filter,evaporator and heater core supported and encased by said lower casingfor conditioning air received from said air inlet prior to the airflowing through said air opening and air ducts.
 12. A cross car duct asset forth in claim 11 wherein said steering column support is amagnesium die cast.
 13. A cross car duct for use in an instrument panelassembly of an automotive vehicle comprising: a contoured upper beamextending longitudinally between a first end and a second end and havinga plurality of air ducts forming air outlets; a contoured lower beamextending longitudinally between a first end and a second end andattached to said upper beam between said respective first and secondends, said lower beam having a plurality of air openings aligned withsaid air ducts of said upper beam; said upper beam including a pluralityof front air ducts defining air openings in fluid communication with afirst air channel formed between said upper and lower beams and a rearair duct defining an air opening in fluid communication with a secondair channel formed between said upper and lower beams; a steering columnsupport affixed to said upper beam and adapted to support steeringcomponents of the vehicle; a mode door operatively connected to saidlower beam adjacent at least one of said air openings; an actuatorsecured to said lower beam and operably connected to said mode door foractuating said mode door between a closed position covering said airopening and an opened position spaced from said air opening for openingsaid air opening to allow passage of air; and a heat, ventilating andair conditioning (HVAC) module secured to said lower beam forcirculating ambient air through selective ones of said air openings andsaid air ducts dependent on said actuator controlling said actuation ofsaid mode door between said opened and closed positions.
 14. A cross carduct as set forth in claim 13 wherein said lower beam includes aplurality of front air openings aligned with said front air ducts and influid communication with said first air channel and a rear air openingaligned with said rear air duct and in fluid communication with saidsecond air channel.
 15. A cross car duct as set forth in claim 14further including a plurality of mode doors pivotally supported by saidhousing of said lower beam for opening and closing said front and rearair openings to the passage of fluid therethrough.
 16. A cross car ductas set forth in claim 15 wherein said HVAC module includes an air inletfor supplying air through said HVAC module to each of said air openingsand air ducts in said respective lower and upper beams.